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REFINERY TANK FARM PACKAGE 6 Document No.
Doc. Type
Discipline
SA-JER-TFAAA-PSCL-508022
PRC
CNS
System
JOB No. 3000235438
BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Revision No.
Remarks
Issued Date
00
ISSUE FOR REVIEW
26-FEB-2010
A.B.PREMKUMAR Prepared By
PAUL WEE Checked By
ALBERT LIEW Approved By
Return Date
Issued By
REFINERY TANK FARM PACKAGE 6 IMPORTANT: No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by means of electronic, mechanical, photocopying, recording, or otherwise, without the written permission of Rotary Engineering Limited.
Revision History Revision
Revision date
Page
Scope of Revision
00
26-FEB-2010
17
ISSUE FOR REVIEW
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 2 of 16
REFINERY TANK FARM PACKAGE 6
TABLE OF CONTENTS 1
SCOPE 4
2
REFERENCE 4
3
DEFINITIONS 5
4
PERSONNEL QUALIFICATION 5
5
GENERAL 5
6
RECEIVING, STORING AND HANDLING OF COATING MATERIALS 5
7
SURFACE PREPARATION 6
8
PREPARATION AND APPLICATION OF COATING MATERIAL 8
9
SHIPPING, HANDLING AND STORAGE OF COATED ITEMS 12
10
INSPECTION AND ACCEPTANCE 12
11
REPAIR OF DEFECTS OR DAMAGES 15
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 3 of 16
REFINERY TANK FARM PACKAGE 6 12
COLOUR SCHEDULE 16
13
HEALTH, SAFETY & ENVIRONMENT 16
14
RECORD 16
15
ATTACHMENTS
16
1. SCOPE This procedure defines the minimum technical requirements of Blasting & Painting for Steel Structures which is required coatings in order to meet Project specification, Coating Manufacturer recommendations, Reference code and standards in REFINERY TANK FARM PACKAGE 6 Project. 2. REFERENCE Document No
Title
SA-JER-TFAAA-PSCL-496501
Project Quality Plan
SA-JER-TRAAA-PSCL-316602
ITP for Blasting and Painting of Structural Steel
SA-JER-TRAAA-PSCL-648020
Blasting and Painting Specification for Steel Structure
JERES-H-001 Rev.5
Coating Selection & Application Requirements for Industrial Plants & Equipment
JERMS-H-9060 Rev.0
Packaging Requirements for Coatings
JERES-H-102 Rev.1
Safety Requirements for Coating Applications
JERMS-M-2007 Rev.3
Fabrication of Structural and Miscellaneous Steel
JERMS-M-2008 Rev.0
Erection of Structural and Miscellaneous Steel
STEEL STRUCTURAL PAINTNG COUNCIL (SSPC) MANUAL: Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 4 of 16
REFINERY TANK FARM PACKAGE 6 SSPC-PA-2
SSPC Method of Measurement of Dry Paint Thickness with Magnetic Gages
SSPC-SP-1
Solvent Cleaning
SSPC-SP-2
Hand Tool Cleaning
SSPC-SP-3
Power Tool Cleaning
SSPC-SP-5
White Metal Blast Cleaning
SSPC-SP-10
Near White Metal Blast Cleaning
---3. DEFINITIONS COMPANY CONTRACTOR
Paint Manufacturer’s Technical Data Sheet –
SAUDI ARAMCO TOTAL Refining and Petrochemical
–
Company (SATORP), Kingdom of Saudi Arabia ROTARY Engineering Ltd (REL) / Petrol Steel Co. Ltd. (PSCL)
4. PERSONNEL QUALIFICATION 4.1.1 All operation shall be performed by skilled workmen 4.1.2 All Coating Inspector shall be qualified as per the requirements specified in Schedule “Q” (Attachment -1) 5. GENERAL Approved Blasting & Painting Specification for Steel structure (Ref. SA-JER-TRAAA-PSCL648020) shall be followed to indentify the followings: Surface to be coated Method of surface preparation Required anchor profile Required coating system Selection of painting materials 6. RECEIVING, STORING AND HANDLING OF COATING MATERIALS All Coating materials shall be delivered to shop by the Coating Manufacturer’s in unopened original containers, good state and correctly labeled as per requirements mentioned in the JERMS-H-9060 (Packaging requirements for coatings). The same shall be ensured by CONTRACTOR Warehouse supervisor & verified by CONTRACTOR Painting Inspector. Technical data sheet shall be supplied, clearly indicating all the features and requirements of the products (i.e. max/min over coating times for the specified DFT, max/min DFT, max temperature resistance etc.). Paints and Thinners shall be stored in well-ventilated building or shelter. Shelter storage temperature shall not exceed 35°C unless stated otherwise in Paint Data Sheet. All paint material must be used within the manufacturer specified period. Paint shall be used in strict rotation according to batch number and shelf life. Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 5 of 16
REFINERY TANK FARM PACKAGE 6
Paints which have exceeded the shelf life shall be set aside and removed from painting storage area. Expired paint shall not be used. The paint materials shall be stored in optimal conditions for their best conservation. Temperature sensitive and self polymerization Paint materials shall be stored in air conditioned storage area. Temporary storage of paint materials covered with canvas, tarpaulins shall not excess 14 days. Paint container showing signs of leakage shall be discarded. Abrasives shall be stored in dry and clean area.
7. SURFACE PREPARATION 7.1 General Any surface that has to be blasted shall be removed of all the contaminants such as oil, greases, chemicals or soil shall be removed prior to blasting by the use of suitable broom brush. During cleaning, all weld areas and attachments shall be given special attention to ensure all welding flux and spatter is removed by the use of files scrapers, chipping, hammers, power or hand brushes or grinders fitted with flexible grinding discs. 7.2 Blast Cleaning Equipment 7.2.1
All blasting equipment shall have current Inspection Certificate from an independent third party and the same will be ensured by the CONTRACTOR Painting Inspector prior to using the equipment.
7.2.2
Abrasive blasting shall be done by using the manual blast cleaning method.
7.2.3
When compressed air is used, air lines shall be provided with effective, well maintained oil and water traps. Efficient well maintained air filters shall be provided to control dust.
7.2.4
The pressure and volume of the compressed air supply for blast cleaning shall be fulfill the requirements of blasting machine manufacturer and suitable for the surface to be blast.
7.2.5
Compressed air supply quality check shall be done by Blotter Test at the start and midpoint of each 8 hour shift. The Blotter Test shall be done as follows, Attach a piece of blotter or absorbent paper to a clip board, then hold it approximately 450-650mm in front of the blast nozzle during air flow only with a nozzle pressure of approximately 50 psig for one minute. Satisfactory results shall be no water or oil contamination on the blotter. The blast system shall be operated for at least 5 minutes under actual field conditions at the specified pressures prior to making the blotter test.
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 6 of 16
REFINERY TANK FARM PACKAGE 6
7.3 Abrasives 7.3.1 Abrasives selection as per SSPC-SP-COM. 7.3.2
Sand or other materials producing silica dust shall not be used.
7.3.3
The abrasives shall be free from oil, grease, moisture etc.
7.3.4
Re-used steel abrasive shall be clean, sharp and free from contaminants. First time prior to start using the re-used steel abrasive shall be showed to CONTRACTOR and COMPANY Inspector for approval. After that CONTRACTOR Painting Inspector will inspect at a regular basis to ensure the quality of the reused steel abrasive shall meet the above requirements.
7.4 Identification 7.4.1 Prior to blasting all material are to be checked to ensure the correct materials are being processed. 7.4.2
Identification marks are to be marked or tagged according to the specific requirement of the project on the materials to be blasted.
7.4.3
Materials are to be identified and have proper storage and placed on designated area before and after blasting/painting.
7.5 Blasting 7.5.1 Blasting shall not be done outside normal daylight work hours unless authorized by COMPANY or CONTRACTOR Inspector. 7.5.2
Blasting operations shall not be carried out unless surfaces to be prepared are 3°C above ambient air dew point.
7.5.3
After blast cleaning and before application of the priming coat the surface shall be cleaned to remove dust and abrasives and in particular from pockets and corners. This can be done by vacuum cleaning or by blowing with dry oil-free compressed air.
7.5.4
Due care shall be exercised to prevent the abrasive grit entering inside equipment and pipe work. On completion of blasting operations, the inside of equipment and piping shall be inspected and cleaned out if the presence of abrasive grit is detected.
7.5.5
Any surface showing signs of handling contamination after basting shall be suitably cleaned and re-blasted.
7.6 Protection of surfaces not to be coated 7.6.1 When using manual blast cleaning method: All the surfaces which are not coated shall be protected from damage and from paint products by adequate temporary coverings during all operations of surface preparations and painting.
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REFINERY TANK FARM PACKAGE 6 7.6.2
In particular, stainless steel and non-ferrous surfaces shall be protected from blasting, overspray and coatings intended for carbon steel. The CONTRACTOR painting supervisor shall ensure protection of all equipment that is not to be painting or liable to be affected by the presence of abrasive or paint. Special attention shall be given to avoid splashes of zinc-based paint on equipment of austenitic steel to prevent high temperature cracking corrosion.
7.7 Weld area and sharp edges 7.7.1 All weld seams, sharp edges and surface irregularities shall be contoured and surface irregularities ground smooth prior to blasting. 7.8 Anchor profile 7.8.1 Anchor profile shall be followed as per Blasting & Painting specification for Steel structural (SA-JER-TRAAA-PSCL-648020), unless otherwise the surface profile for carbon steel surfaces after blast cleaning shall have a min/max height of 50/70 microns with rough peaks to 100 microns (Rz). 7.9 Inspection 7.9.1 After completion of surface preparation, the CONTRACTOR Painting Inspector shall carry out the inspection activities as per Section-10 in this procedure. 8. PREPARATION AND APPLICATION OF COATING MATERIAL 8.1 General 8.1.1 The Selection of Coating systems & Coating materials shall be strictly followed as per Blasting & Painting Specification for Steel structural (Ref. SA-JER-TRAAAPSCL-648020) and the same shall be ensured by the CONTRACTOR Painting Inspector. 8.1.2
CONTRACTOR Painting Inspector & Painting Supervisor shall strictly follow the instructions and recommendations as prescribed by the Coating Manufacturers for the preparation and application of all coating materials.
8.2 Coating Equipment 8.2.1 All Painting equipment shall have current inspection certificate from an independent third party and the same will ensure by the Contractor Painting Inspector prior to use the equipment. 8.2.2
All Painting equipment to be checked to ensure that there is no residual paint from previous application in the containers or hoses and paint guns.
8.2.3
The pressure and volume of the compressed air supply for spray application shall fulfill the requirements of Spray machine and Painting Manufactures
8.2.4
When compressed air is used, air lines shall be provided with effective, well maintained oil and water traps. Efficient well maintained air filters shall be provided to control dust.
8.3 Weather Conditions Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 8 of 16
REFINERY TANK FARM PACKAGE 6 8.3.1
The CONTRACTOR Painting Inspector shall measure and recorded the local conditions of temperature and humidity during blasting, painting and curing.
8.3.2
Coating shall only be applied when suitable weather conditions prevail and the same will be ensured by CONTRACTOR Painting Inspector.
8.3.3
Coating shall not be applied under the following conditions or when such conditions are likely to prevail before the coating is cured: At temperatures below 10°C for (or according to Coating Manufacturer recommendation) or when the temperature is likely to fall below this figure before the surface film is dry or on surfaces ing low temperatures. When the relative humidity of the atmosphere exceeds 85% The steel temperature is less than 3°C above the dew point During foggy or misty conditions Before dew or moisture has evaporated When it is raining or rain is imminent
8.3.4
CONTRACTOR Painting Supervisor shall be responsible for scheduling his activities under consideration of suitable weather and other atmospheric conditions.
8.3.5
Coating which is contaminated during curing, for example by dust, condensation or rain, shall, if deemed necessary by COMPANY or CONTRACTOR Painting Inspector be removed and redone.
8.4 Coating Material Preparation 8.4.1 Only if the conditions required in section 8.3 of this procedure are met, coating of the item or part or component to be allowed. 8.4.2
Coating for two-pack or multiple packs coating system shall be mixed in the proportions and under the conditions recommended by the Manufacturer.
8.4.3
The mixed coating shall be used within the regulated pot life and shall not be used on expiry of its “pot life”.
8.4.4
Coating components shall be power-stirred to obtain a homogenous consistency. No hand stirring is allowed for quantities greater than 5 liters. Before further use, coating shall be allowed to stand for a time long enough to remove aeration caused by stirring.
8.4.5
For inorganic zinc primers, after mixing the silicate binder and the zinc powder, the mixed product shall be sieved prior to application and continuously powerstirred during application.
8.4.6
The mixed coating shall match with other prepared products of the same coat.
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REFINERY TANK FARM PACKAGE 6
8.5 Coating Application 8.5.1 Painting shall be done according to the application instruction of the Coating Manufacturer and shall be performed by skilled and experienced staff with suitable Personal Protection Equipment (PPE). 8.5.2
All personnel entering in to the blasted surfaces shall wear rubber-soled shoes with clean disposable covers, sweet bands and dirt-free gloves.
8.5.3
Coating may be applied by the following four methods as approved or specified by the coating Manufacturer,
Airless Spray and conventional Spray Application When using conventional spray or airless spray methods, all the equipment shall have adequate, well-maintained pressure regulating devices, effective strainers, traps and separators, suitable size hoses and clean, well-maintained guns. The traps and separators for removing oil and water maintained from the compressed air shall be such that air atomizing guns will not deposit oil or water when directed on to a clean surface for 15 seconds. For airless spray the size of spray nozzle tips, air pressure, etc., shall be used as per the Paint Data Sheet and recommended by the equipment supplier. The area sprayed should be within a comfortable distance of the operator to avoid a long traverse of the jet or arcing of the gun. Each coat shall be applied uniformly and completely over the entire surface. All skips, runs, drips and sags shall be brushed out immediately
Due care shall be exercised whilst spraying to prevent overspray and contamination of other surfaces by the use of shields, etc. Brush and Roller Application Brush application may be used under the following circumstances: When area cannot be coated properly by spraying for any reason, such as material or environmental considerations. For the initial coat of paint to corners, edges, crevices, holes, weld or irregular surfaces prior to spray application. For “touch up” to localized damaged areas
Brush or rollers used shall be of a suitable size and shape and shall be kept clean by use of Paint Manufacturer’s recommended solvents.
Where rollers are used, the nap shall be of sufficient length to work the coating well in the surface.
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Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
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REFINERY TANK FARM PACKAGE 6
Roller application shall be in accordance with the paint Manufacturer’s instructions.
The specified coating thickness shall be achieved at all protrusions, corners and crevices. Edges, cracks, bolt heads, etc. may require the coating to be evened by lying off with a brush after roller application.
8.6 Priming 8.6.1 The priming coat shall be applied as soon as possible after the surface preparation has been carried out and before any contamination of the cleaned surface. 8.6.2
Prepared/unprepared welding/plate edges and surfaces within 50 mm to 75mm of edge shall be left uncoated or shall be coated with an approved welding primer only.
8.6.3
Angles, corners, sharp edges, bolt or rivet heads, weld seams and other surface irregularities shall be stripe-coated by brush. This coat shall be the same product as the primer.
8.6.4
After completion of Primer coat, CONTRACTOR Painting Inspector shall perform the inspection as per Section 10 in this procedure.
8.7 Subsequent coat (If any) 8.7.1 When the tank erection/welding/Testing are completed, the surface shall be checked by CONTRACTOR Painting Inspector and the damaged areas shall be repaired with the same primer or Manufacturers’ recommended coatings. 8.7.2
When more than one coat is required, the Coating recommendations on over coating time shall be complied with.
Manufacturer’s
8.7.3
Wet film thickness shall be checked during coating by painter to ensure that the full coating thickness will be achieved in the specified number of coats (as recommended by the Coating Manufacturer).
8.7.4
A final coat shall be applied in accordance with the undercoat over coating time recommended by the Coating Manufacturer
8.7.5
The final coat shall provided a smooth, even finished coating surface, where gloss finish coats are applied, the surface shall be a smooth gloss finish with no breaks in the surface.
8.8 Drying times Each coat shall be allowed to cure thoroughly in accordance with the Coating Manufacturer’s instruction for over coating before the next coat is applied. Curing times are highly dependent on local conditions. 8.9 Contrasting coatings Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
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REFINERY TANK FARM PACKAGE 6 Where it is necessary to apply more than one coat of a particular product to obtain a specified dry film thickness, then the first coat shall be selected sufficiently different in color, in order to distinguish from the subsequent coats. 8.10Items also to be Painted before installation 8.10.1 All Surfaces that will be inaccessible after assembly or installation shall be cleaned and coated before installation at shop. Such surfaces include underneath or base plate, skids, saddles, skirts, bored/punched holes in steel , flange screw holes, etc., 8.10.2 Metal surfaces “i.e. bolted ts in structures” – should be coated with one full layer of the specified primer on both surfaces immediately before bolting up. Fretting surfaces where friction grip is required shall not be coated. 8.10.3 When painting is carried out before installation, all reasonable steps as mentioned in section 9 in this procedure shall be taken by CONTRACTOR Painting Supervisor to reduce damage to the coating system before and during installation and the same will be ensure by the CONTRACTOR Painting Inspector. 9. SHIPPING, HANDLING AND STORAGE OF COATED ITEMS Coated items shall not be handled or moved until all coatings have been properly dried or cured as required in the Coating Manufacturer’s instructions.
Coated items shall be handled with equipment such as wide belt slings, web belts, and wide padded skids selected to prevent damage to the coating.
Handling equipment likely to cause damage to the coating shall not be used.
Items such as chains, cables, hooks, tongs, metal bars and narrow skids shall not be permitted to come in with the coating.
Dragging or skidding in coated items shall not be permitted
Coated items shall be loaded, padded, and secured for transport in such a manner that the coating will not be damaged in transit.
Coated items shall be separated so that the items do not bear against each other.
Coated items shall be stacked off the ground using suitable means (e.g. parallel height ridges of rock-free sand, wooden timbers placed under the uncoated pipe ends) to avoid damages of the coating.
10. INSPECTION AND ACCEPTANCE 10.1 General 10.1.1 All Inspection activity shall be carried out as per the approved Project Quality Plan (Ref. SA-JER-TFAAA-PSCL-496501) in the various phases of execution and inspection. Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 12 of 16
REFINERY TANK FARM PACKAGE 6 10.1.2 Request for Inspection (RFI) shall be raised to COMPANY for inspection as per the approved Blasting and Painting ITP for Steel structural (Ref. SA-JER-TF661PSCL-316602). 10.2 Inspection of Surface Preparation 10.2.1 COMPANY approved CONTRACTOR Painting Inspector shall check the surface of the blasted materials as per required surface preparation and ensure the clean surface must be free from mill scale, oil, grease, soil, cement, salt, acids or other corrosive chemical, which are harmful for painting. 10.2.2 Inspection frequency for cleaning of rust etc. shall be one in each area where surface preparation has been completed, regardless large or small, before coating. 10.2.3 Anchor pattern shall be inspected by using Testex Tape (Press-O-Film) at where surface preparation has been completed. 10.2.4 Anchor profile value shall be inspected in Testex tape by using calibrated Dial gauge Micro meter. The values shall be within the acceptable limit given in Section 7.8 in this procedure. This shall be ensured by CONTRACTOR Painting Inspector and the Testex Tape shall be attach with the Painting inspection Report (Ref. PSCL-SATORP-QAQC-010) 10.3 Inspection of Coating application 10.3.1 The following inspection and testing shall be performed during the application coating system: Checking on raw materials (integrity of packing, expiry dates etc.) Checking of paints documentations (Technical Data Sheet, Material Safety Data Sheet) Checking of meteorological and environmental conditions as per sec 8.3 in this procedure 10.3.2 Thickness Check Coating film thickness shall be measured for the following items: INSPECTION FREQUENCY
INSPECTION IMPLEMENTATION
S.No.
INSPECTION ITEM
1
Wet Film Thickness
One point / 5 -20 m² (Min. 10 pints / Day)
Wet Film Thickness gauge
2
Dry Film Thickness
One point / 3 – 5 m² (One point / 10 m² for tank plates & equipment larger than 10mtr diameter)
Dry Film Thickness gauge (e.g. Elecometer or Microtest etc.)
3
Corners
100%
Inspection mirror
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Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
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REFINERY TANK FARM PACKAGE 6 Measurement of wet film thickness (WFT) has to be done only for reference and shall not be recorded. Measurement shall be carried out at least three times at each measuring point. The average of three measurements shall be recorded as the measured value for the item concerned. Thickness gauges to be used for measurement of paint films shall be calibrated with Standard specimens once in the morning, afternoon and night (if working) or in accordance with the coating Manufacturers’ recommendations. Measurement of film thickness is less than 80% of the nominal dry film thickness (DFT) is not acceptable. If the dry film thickness does not meet the specified value, additional coats shall be applied as per section 11 in this procedure, except for inorganic zinc (zinc silicate) primers that shall be re-blasted and re-applied at the required dry film thickness (DFT) Inorganic zinc (zinc silicate) primers applied at dry film thickness greater than 100µm or showing mud-cracking shall also be re-blasted and re-applied at the required DFT. 10.3.3 Drying / Curing For each coat, the Drying/Curing shall be checked as per the Manufacturers’ Product Data Sheet and the same shall be ensured by the CONTRACTOR Painting Inspector. 10.3.4 Adhesion check As per the Coating Manufacture’s recommended, Adhesion Pull-off test shall be done on test s, which are to be cleaned and coated at the same time as the surface being coated.
One test shall be prepared and tested for each Painting System as specified in the Blasting & Painting Specification for Steel structural (Ref. SA-JER-TRAAA-PSCL-648020). And also adhesion pull-off test shall be carried out at any location where there is evidence of any sort of failure in any coating including, but not limited to, lifting of coats or loss of adhesion between layers in coating system.
The adhesion pull-off test shall be conducted accordance with ASTM D4541. The Coating which adhesion pull off test result is less than 30kg/cm² (3MPa) shall be considered to have failed.
10.3.5 Porosity check Film continuity shall be checked as follows,
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REFINERY TANK FARM PACKAGE 6
Visual Inspection for holidays, pinholes, and excessive overspray shall be done by CONTRACTOR Painting Inspector for every subsequent coat and after completion of Final coat.
Areas found to have been improperly coated shall be reapplied as per section 11 in this procedure.
10.3.6 Soluble salt contamination This test shall be done, once for every different Grade Material after surface preparation has been completed and prior to coating application. Testing for chloride and soluble salt concentrations shall be done using a Bresle Method according to ISO 8502-6. The pH level shall be find using of pH paper or pH meter. The chloride and soluble salt concentrations shall be less than 10 ppm and the pH shall be natural (between 6 and 8). When the above ppm & pH levels are exceeded, the surfaces shall be either steam cleaned or high pressure water washed before blasting. The cleaned surface shall be retested to that the contaminant levels are within the acceptable range. The above test shall be carried out by the CONTRACTOR Painting Inspector and the result shall be recorded in the Coating/Blasting report (Ref. ATTACHMENT-1). 10.3.7 Testing Equipment Testing equipment shall be properly calibrated as per the Project Equipment Calibration Procedure (Ref. SA-JER-TFAAA-PSCL-506669). 11. REPAIR OF DEFECTS OR DAMAGES 11.1 Any defect or damage that may occur shall be repaired before the application of further coats. 11.2
Areas which are to be over coated shall be thoroughly cleaned free from grease, oil and other contaminants and shall be dry.
11.3
The surfaces shall then be prepared to the standard as specified. Edges of sound coating around the repair area shall be feathered back approximately 50 mm for a smooth transition. If necessary, vacuum blasting equipment shall be used for surface preparation.
11.4
Subsequently additional compatible coats shall be applied (if required), until they meet the specification. Those additional coats shall blend in with final coating on adjacent area
11.5
Damaged surface shall be touchup with the coating as per the approved specification (Ref. SA-JER-TRAAA-PSCL-648020) or Coating Manufacturers’ Recommended paints shall be used. The repair coat shall overlap sound coating.
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REFINERY TANK FARM PACKAGE 6
12. COLOUR SCHEDULE 12.1 The coating colour shall be strictly followed as per the COMPANY approved Blasting & Painting Specification for Steel structural (Ref. SA-JER-TRAAA-PSCL-648020). 13. HEALTH, SAFETY & ENVIRONMENT 13.1
All work shall strictly comply with Project Health, Safety & Environmental Plan (SAJER-TFAAA-PSCL-498143) and Shop Safety Rules & Regulations. Grit blast hoses and nozzle shall be grounded to dissipate a static electric charge.
13.2
Anti-whip devices shall be fitted to all air hoses.
13.3
Safety shields, helmets, goggles, respirators, ear protection and protective clothing shall be use or worn then and where necessary during all operations.
13.4
Material Safety Data Sheet shall be always available at coating area for ready reference.
13.5
Only competent personnel are permitted to operate the equipment and such persons shall be tested by a competent person.
13.6
To prevent uncontrolled and reduce air emissions, the works shall be conducted in a controlled environment.
13.7
Abrasive shall be reused where possible, so as to reduce waste generated.
13.8
Waste generated such as paint containers, spent abrasive shall be properly stored prior to removal by approved waste collectors.
14. RECORD 14.1 The entire process shall be assured by CONTRACTOR PAINTING INSPECTOR by recording all the variables in the Blasting / Coating Report – PSCL-SATORP-QAQC010 (Ref. Attachment -1) 15. ATTACHMENTS 15.1 ATTACHMENTS – 1 Blasting / Coating Report (PSCL-SATORP-QAQC-010)
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Doc. Type
Discipline
SA-JER-TFAAA-PSCL-508022
PRC
CNS
System
JOB No. 3000235438
BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Revision No.
Remarks
Issued Date
00
ISSUE FOR REVIEW
26-FEB-2010
A.B.PREMKUMAR Prepared By
PAUL WEE Checked By
ALBERT LIEW Approved By
Return Date
Issued By
REFINERY TANK FARM PACKAGE 6 IMPORTANT: No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by means of electronic, mechanical, photocopying, recording, or otherwise, without the written permission of Rotary Engineering Limited.
Revision History Revision
Revision date
Page
Scope of Revision
00
26-FEB-2010
17
ISSUE FOR REVIEW
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
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REFINERY TANK FARM PACKAGE 6
TABLE OF CONTENTS 1
SCOPE 4
2
REFERENCE 4
3
DEFINITIONS 5
4
PERSONNEL QUALIFICATION 5
5
GENERAL 5
6
RECEIVING, STORING AND HANDLING OF COATING MATERIALS 5
7
SURFACE PREPARATION 6
8
PREPARATION AND APPLICATION OF COATING MATERIAL 8
9
SHIPPING, HANDLING AND STORAGE OF COATED ITEMS 12
10
INSPECTION AND ACCEPTANCE 12
11
REPAIR OF DEFECTS OR DAMAGES 15
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REFINERY TANK FARM PACKAGE 6 12
COLOUR SCHEDULE 16
13
HEALTH, SAFETY & ENVIRONMENT 16
14
RECORD 16
15
ATTACHMENTS
16
1. SCOPE This procedure defines the minimum technical requirements of Blasting & Painting for Steel Structures which is required coatings in order to meet Project specification, Coating Manufacturer recommendations, Reference code and standards in REFINERY TANK FARM PACKAGE 6 Project. 2. REFERENCE Document No
Title
SA-JER-TFAAA-PSCL-496501
Project Quality Plan
SA-JER-TRAAA-PSCL-316602
ITP for Blasting and Painting of Structural Steel
SA-JER-TRAAA-PSCL-648020
Blasting and Painting Specification for Steel Structure
JERES-H-001 Rev.5
Coating Selection & Application Requirements for Industrial Plants & Equipment
JERMS-H-9060 Rev.0
Packaging Requirements for Coatings
JERES-H-102 Rev.1
Safety Requirements for Coating Applications
JERMS-M-2007 Rev.3
Fabrication of Structural and Miscellaneous Steel
JERMS-M-2008 Rev.0
Erection of Structural and Miscellaneous Steel
STEEL STRUCTURAL PAINTNG COUNCIL (SSPC) MANUAL: Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 4 of 16
REFINERY TANK FARM PACKAGE 6 SSPC-PA-2
SSPC Method of Measurement of Dry Paint Thickness with Magnetic Gages
SSPC-SP-1
Solvent Cleaning
SSPC-SP-2
Hand Tool Cleaning
SSPC-SP-3
Power Tool Cleaning
SSPC-SP-5
White Metal Blast Cleaning
SSPC-SP-10
Near White Metal Blast Cleaning
---3. DEFINITIONS COMPANY CONTRACTOR
Paint Manufacturer’s Technical Data Sheet –
SAUDI ARAMCO TOTAL Refining and Petrochemical
–
Company (SATORP), Kingdom of Saudi Arabia ROTARY Engineering Ltd (REL) / Petrol Steel Co. Ltd. (PSCL)
4. PERSONNEL QUALIFICATION 4.1.1 All operation shall be performed by skilled workmen 4.1.2 All Coating Inspector shall be qualified as per the requirements specified in Schedule “Q” (Attachment -1) 5. GENERAL Approved Blasting & Painting Specification for Steel structure (Ref. SA-JER-TRAAA-PSCL648020) shall be followed to indentify the followings: Surface to be coated Method of surface preparation Required anchor profile Required coating system Selection of painting materials 6. RECEIVING, STORING AND HANDLING OF COATING MATERIALS All Coating materials shall be delivered to shop by the Coating Manufacturer’s in unopened original containers, good state and correctly labeled as per requirements mentioned in the JERMS-H-9060 (Packaging requirements for coatings). The same shall be ensured by CONTRACTOR Warehouse supervisor & verified by CONTRACTOR Painting Inspector. Technical data sheet shall be supplied, clearly indicating all the features and requirements of the products (i.e. max/min over coating times for the specified DFT, max/min DFT, max temperature resistance etc.). Paints and Thinners shall be stored in well-ventilated building or shelter. Shelter storage temperature shall not exceed 35°C unless stated otherwise in Paint Data Sheet. All paint material must be used within the manufacturer specified period. Paint shall be used in strict rotation according to batch number and shelf life. Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 5 of 16
REFINERY TANK FARM PACKAGE 6
Paints which have exceeded the shelf life shall be set aside and removed from painting storage area. Expired paint shall not be used. The paint materials shall be stored in optimal conditions for their best conservation. Temperature sensitive and self polymerization Paint materials shall be stored in air conditioned storage area. Temporary storage of paint materials covered with canvas, tarpaulins shall not excess 14 days. Paint container showing signs of leakage shall be discarded. Abrasives shall be stored in dry and clean area.
7. SURFACE PREPARATION 7.1 General Any surface that has to be blasted shall be removed of all the contaminants such as oil, greases, chemicals or soil shall be removed prior to blasting by the use of suitable broom brush. During cleaning, all weld areas and attachments shall be given special attention to ensure all welding flux and spatter is removed by the use of files scrapers, chipping, hammers, power or hand brushes or grinders fitted with flexible grinding discs. 7.2 Blast Cleaning Equipment 7.2.1
All blasting equipment shall have current Inspection Certificate from an independent third party and the same will be ensured by the CONTRACTOR Painting Inspector prior to using the equipment.
7.2.2
Abrasive blasting shall be done by using the manual blast cleaning method.
7.2.3
When compressed air is used, air lines shall be provided with effective, well maintained oil and water traps. Efficient well maintained air filters shall be provided to control dust.
7.2.4
The pressure and volume of the compressed air supply for blast cleaning shall be fulfill the requirements of blasting machine manufacturer and suitable for the surface to be blast.
7.2.5
Compressed air supply quality check shall be done by Blotter Test at the start and midpoint of each 8 hour shift. The Blotter Test shall be done as follows, Attach a piece of blotter or absorbent paper to a clip board, then hold it approximately 450-650mm in front of the blast nozzle during air flow only with a nozzle pressure of approximately 50 psig for one minute. Satisfactory results shall be no water or oil contamination on the blotter. The blast system shall be operated for at least 5 minutes under actual field conditions at the specified pressures prior to making the blotter test.
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 6 of 16
REFINERY TANK FARM PACKAGE 6
7.3 Abrasives 7.3.1 Abrasives selection as per SSPC-SP-COM. 7.3.2
Sand or other materials producing silica dust shall not be used.
7.3.3
The abrasives shall be free from oil, grease, moisture etc.
7.3.4
Re-used steel abrasive shall be clean, sharp and free from contaminants. First time prior to start using the re-used steel abrasive shall be showed to CONTRACTOR and COMPANY Inspector for approval. After that CONTRACTOR Painting Inspector will inspect at a regular basis to ensure the quality of the reused steel abrasive shall meet the above requirements.
7.4 Identification 7.4.1 Prior to blasting all material are to be checked to ensure the correct materials are being processed. 7.4.2
Identification marks are to be marked or tagged according to the specific requirement of the project on the materials to be blasted.
7.4.3
Materials are to be identified and have proper storage and placed on designated area before and after blasting/painting.
7.5 Blasting 7.5.1 Blasting shall not be done outside normal daylight work hours unless authorized by COMPANY or CONTRACTOR Inspector. 7.5.2
Blasting operations shall not be carried out unless surfaces to be prepared are 3°C above ambient air dew point.
7.5.3
After blast cleaning and before application of the priming coat the surface shall be cleaned to remove dust and abrasives and in particular from pockets and corners. This can be done by vacuum cleaning or by blowing with dry oil-free compressed air.
7.5.4
Due care shall be exercised to prevent the abrasive grit entering inside equipment and pipe work. On completion of blasting operations, the inside of equipment and piping shall be inspected and cleaned out if the presence of abrasive grit is detected.
7.5.5
Any surface showing signs of handling contamination after basting shall be suitably cleaned and re-blasted.
7.6 Protection of surfaces not to be coated 7.6.1 When using manual blast cleaning method: All the surfaces which are not coated shall be protected from damage and from paint products by adequate temporary coverings during all operations of surface preparations and painting.
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 7 of 16
REFINERY TANK FARM PACKAGE 6 7.6.2
In particular, stainless steel and non-ferrous surfaces shall be protected from blasting, overspray and coatings intended for carbon steel. The CONTRACTOR painting supervisor shall ensure protection of all equipment that is not to be painting or liable to be affected by the presence of abrasive or paint. Special attention shall be given to avoid splashes of zinc-based paint on equipment of austenitic steel to prevent high temperature cracking corrosion.
7.7 Weld area and sharp edges 7.7.1 All weld seams, sharp edges and surface irregularities shall be contoured and surface irregularities ground smooth prior to blasting. 7.8 Anchor profile 7.8.1 Anchor profile shall be followed as per Blasting & Painting specification for Steel structural (SA-JER-TRAAA-PSCL-648020), unless otherwise the surface profile for carbon steel surfaces after blast cleaning shall have a min/max height of 50/70 microns with rough peaks to 100 microns (Rz). 7.9 Inspection 7.9.1 After completion of surface preparation, the CONTRACTOR Painting Inspector shall carry out the inspection activities as per Section-10 in this procedure. 8. PREPARATION AND APPLICATION OF COATING MATERIAL 8.1 General 8.1.1 The Selection of Coating systems & Coating materials shall be strictly followed as per Blasting & Painting Specification for Steel structural (Ref. SA-JER-TRAAAPSCL-648020) and the same shall be ensured by the CONTRACTOR Painting Inspector. 8.1.2
CONTRACTOR Painting Inspector & Painting Supervisor shall strictly follow the instructions and recommendations as prescribed by the Coating Manufacturers for the preparation and application of all coating materials.
8.2 Coating Equipment 8.2.1 All Painting equipment shall have current inspection certificate from an independent third party and the same will ensure by the Contractor Painting Inspector prior to use the equipment. 8.2.2
All Painting equipment to be checked to ensure that there is no residual paint from previous application in the containers or hoses and paint guns.
8.2.3
The pressure and volume of the compressed air supply for spray application shall fulfill the requirements of Spray machine and Painting Manufactures
8.2.4
When compressed air is used, air lines shall be provided with effective, well maintained oil and water traps. Efficient well maintained air filters shall be provided to control dust.
8.3 Weather Conditions Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 8 of 16
REFINERY TANK FARM PACKAGE 6 8.3.1
The CONTRACTOR Painting Inspector shall measure and recorded the local conditions of temperature and humidity during blasting, painting and curing.
8.3.2
Coating shall only be applied when suitable weather conditions prevail and the same will be ensured by CONTRACTOR Painting Inspector.
8.3.3
Coating shall not be applied under the following conditions or when such conditions are likely to prevail before the coating is cured: At temperatures below 10°C for (or according to Coating Manufacturer recommendation) or when the temperature is likely to fall below this figure before the surface film is dry or on surfaces ing low temperatures. When the relative humidity of the atmosphere exceeds 85% The steel temperature is less than 3°C above the dew point During foggy or misty conditions Before dew or moisture has evaporated When it is raining or rain is imminent
8.3.4
CONTRACTOR Painting Supervisor shall be responsible for scheduling his activities under consideration of suitable weather and other atmospheric conditions.
8.3.5
Coating which is contaminated during curing, for example by dust, condensation or rain, shall, if deemed necessary by COMPANY or CONTRACTOR Painting Inspector be removed and redone.
8.4 Coating Material Preparation 8.4.1 Only if the conditions required in section 8.3 of this procedure are met, coating of the item or part or component to be allowed. 8.4.2
Coating for two-pack or multiple packs coating system shall be mixed in the proportions and under the conditions recommended by the Manufacturer.
8.4.3
The mixed coating shall be used within the regulated pot life and shall not be used on expiry of its “pot life”.
8.4.4
Coating components shall be power-stirred to obtain a homogenous consistency. No hand stirring is allowed for quantities greater than 5 liters. Before further use, coating shall be allowed to stand for a time long enough to remove aeration caused by stirring.
8.4.5
For inorganic zinc primers, after mixing the silicate binder and the zinc powder, the mixed product shall be sieved prior to application and continuously powerstirred during application.
8.4.6
The mixed coating shall match with other prepared products of the same coat.
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 9 of 16
REFINERY TANK FARM PACKAGE 6
8.5 Coating Application 8.5.1 Painting shall be done according to the application instruction of the Coating Manufacturer and shall be performed by skilled and experienced staff with suitable Personal Protection Equipment (PPE). 8.5.2
All personnel entering in to the blasted surfaces shall wear rubber-soled shoes with clean disposable covers, sweet bands and dirt-free gloves.
8.5.3
Coating may be applied by the following four methods as approved or specified by the coating Manufacturer,
Airless Spray and conventional Spray Application When using conventional spray or airless spray methods, all the equipment shall have adequate, well-maintained pressure regulating devices, effective strainers, traps and separators, suitable size hoses and clean, well-maintained guns. The traps and separators for removing oil and water maintained from the compressed air shall be such that air atomizing guns will not deposit oil or water when directed on to a clean surface for 15 seconds. For airless spray the size of spray nozzle tips, air pressure, etc., shall be used as per the Paint Data Sheet and recommended by the equipment supplier. The area sprayed should be within a comfortable distance of the operator to avoid a long traverse of the jet or arcing of the gun. Each coat shall be applied uniformly and completely over the entire surface. All skips, runs, drips and sags shall be brushed out immediately
Due care shall be exercised whilst spraying to prevent overspray and contamination of other surfaces by the use of shields, etc. Brush and Roller Application Brush application may be used under the following circumstances: When area cannot be coated properly by spraying for any reason, such as material or environmental considerations. For the initial coat of paint to corners, edges, crevices, holes, weld or irregular surfaces prior to spray application. For “touch up” to localized damaged areas
Brush or rollers used shall be of a suitable size and shape and shall be kept clean by use of Paint Manufacturer’s recommended solvents.
Where rollers are used, the nap shall be of sufficient length to work the coating well in the surface.
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 10 of 16
REFINERY TANK FARM PACKAGE 6
Roller application shall be in accordance with the paint Manufacturer’s instructions.
The specified coating thickness shall be achieved at all protrusions, corners and crevices. Edges, cracks, bolt heads, etc. may require the coating to be evened by lying off with a brush after roller application.
8.6 Priming 8.6.1 The priming coat shall be applied as soon as possible after the surface preparation has been carried out and before any contamination of the cleaned surface. 8.6.2
Prepared/unprepared welding/plate edges and surfaces within 50 mm to 75mm of edge shall be left uncoated or shall be coated with an approved welding primer only.
8.6.3
Angles, corners, sharp edges, bolt or rivet heads, weld seams and other surface irregularities shall be stripe-coated by brush. This coat shall be the same product as the primer.
8.6.4
After completion of Primer coat, CONTRACTOR Painting Inspector shall perform the inspection as per Section 10 in this procedure.
8.7 Subsequent coat (If any) 8.7.1 When the tank erection/welding/Testing are completed, the surface shall be checked by CONTRACTOR Painting Inspector and the damaged areas shall be repaired with the same primer or Manufacturers’ recommended coatings. 8.7.2
When more than one coat is required, the Coating recommendations on over coating time shall be complied with.
Manufacturer’s
8.7.3
Wet film thickness shall be checked during coating by painter to ensure that the full coating thickness will be achieved in the specified number of coats (as recommended by the Coating Manufacturer).
8.7.4
A final coat shall be applied in accordance with the undercoat over coating time recommended by the Coating Manufacturer
8.7.5
The final coat shall provided a smooth, even finished coating surface, where gloss finish coats are applied, the surface shall be a smooth gloss finish with no breaks in the surface.
8.8 Drying times Each coat shall be allowed to cure thoroughly in accordance with the Coating Manufacturer’s instruction for over coating before the next coat is applied. Curing times are highly dependent on local conditions. 8.9 Contrasting coatings Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 11 of 16
REFINERY TANK FARM PACKAGE 6 Where it is necessary to apply more than one coat of a particular product to obtain a specified dry film thickness, then the first coat shall be selected sufficiently different in color, in order to distinguish from the subsequent coats. 8.10Items also to be Painted before installation 8.10.1 All Surfaces that will be inaccessible after assembly or installation shall be cleaned and coated before installation at shop. Such surfaces include underneath or base plate, skids, saddles, skirts, bored/punched holes in steel , flange screw holes, etc., 8.10.2 Metal surfaces “i.e. bolted ts in structures” – should be coated with one full layer of the specified primer on both surfaces immediately before bolting up. Fretting surfaces where friction grip is required shall not be coated. 8.10.3 When painting is carried out before installation, all reasonable steps as mentioned in section 9 in this procedure shall be taken by CONTRACTOR Painting Supervisor to reduce damage to the coating system before and during installation and the same will be ensure by the CONTRACTOR Painting Inspector. 9. SHIPPING, HANDLING AND STORAGE OF COATED ITEMS Coated items shall not be handled or moved until all coatings have been properly dried or cured as required in the Coating Manufacturer’s instructions.
Coated items shall be handled with equipment such as wide belt slings, web belts, and wide padded skids selected to prevent damage to the coating.
Handling equipment likely to cause damage to the coating shall not be used.
Items such as chains, cables, hooks, tongs, metal bars and narrow skids shall not be permitted to come in with the coating.
Dragging or skidding in coated items shall not be permitted
Coated items shall be loaded, padded, and secured for transport in such a manner that the coating will not be damaged in transit.
Coated items shall be separated so that the items do not bear against each other.
Coated items shall be stacked off the ground using suitable means (e.g. parallel height ridges of rock-free sand, wooden timbers placed under the uncoated pipe ends) to avoid damages of the coating.
10. INSPECTION AND ACCEPTANCE 10.1 General 10.1.1 All Inspection activity shall be carried out as per the approved Project Quality Plan (Ref. SA-JER-TFAAA-PSCL-496501) in the various phases of execution and inspection. Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 12 of 16
REFINERY TANK FARM PACKAGE 6 10.1.2 Request for Inspection (RFI) shall be raised to COMPANY for inspection as per the approved Blasting and Painting ITP for Steel structural (Ref. SA-JER-TF661PSCL-316602). 10.2 Inspection of Surface Preparation 10.2.1 COMPANY approved CONTRACTOR Painting Inspector shall check the surface of the blasted materials as per required surface preparation and ensure the clean surface must be free from mill scale, oil, grease, soil, cement, salt, acids or other corrosive chemical, which are harmful for painting. 10.2.2 Inspection frequency for cleaning of rust etc. shall be one in each area where surface preparation has been completed, regardless large or small, before coating. 10.2.3 Anchor pattern shall be inspected by using Testex Tape (Press-O-Film) at where surface preparation has been completed. 10.2.4 Anchor profile value shall be inspected in Testex tape by using calibrated Dial gauge Micro meter. The values shall be within the acceptable limit given in Section 7.8 in this procedure. This shall be ensured by CONTRACTOR Painting Inspector and the Testex Tape shall be attach with the Painting inspection Report (Ref. PSCL-SATORP-QAQC-010) 10.3 Inspection of Coating application 10.3.1 The following inspection and testing shall be performed during the application coating system: Checking on raw materials (integrity of packing, expiry dates etc.) Checking of paints documentations (Technical Data Sheet, Material Safety Data Sheet) Checking of meteorological and environmental conditions as per sec 8.3 in this procedure 10.3.2 Thickness Check Coating film thickness shall be measured for the following items: INSPECTION FREQUENCY
INSPECTION IMPLEMENTATION
S.No.
INSPECTION ITEM
1
Wet Film Thickness
One point / 5 -20 m² (Min. 10 pints / Day)
Wet Film Thickness gauge
2
Dry Film Thickness
One point / 3 – 5 m² (One point / 10 m² for tank plates & equipment larger than 10mtr diameter)
Dry Film Thickness gauge (e.g. Elecometer or Microtest etc.)
3
Corners
100%
Inspection mirror
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 13 of 16
REFINERY TANK FARM PACKAGE 6 Measurement of wet film thickness (WFT) has to be done only for reference and shall not be recorded. Measurement shall be carried out at least three times at each measuring point. The average of three measurements shall be recorded as the measured value for the item concerned. Thickness gauges to be used for measurement of paint films shall be calibrated with Standard specimens once in the morning, afternoon and night (if working) or in accordance with the coating Manufacturers’ recommendations. Measurement of film thickness is less than 80% of the nominal dry film thickness (DFT) is not acceptable. If the dry film thickness does not meet the specified value, additional coats shall be applied as per section 11 in this procedure, except for inorganic zinc (zinc silicate) primers that shall be re-blasted and re-applied at the required dry film thickness (DFT) Inorganic zinc (zinc silicate) primers applied at dry film thickness greater than 100µm or showing mud-cracking shall also be re-blasted and re-applied at the required DFT. 10.3.3 Drying / Curing For each coat, the Drying/Curing shall be checked as per the Manufacturers’ Product Data Sheet and the same shall be ensured by the CONTRACTOR Painting Inspector. 10.3.4 Adhesion check As per the Coating Manufacture’s recommended, Adhesion Pull-off test shall be done on test s, which are to be cleaned and coated at the same time as the surface being coated.
One test shall be prepared and tested for each Painting System as specified in the Blasting & Painting Specification for Steel structural (Ref. SA-JER-TRAAA-PSCL-648020). And also adhesion pull-off test shall be carried out at any location where there is evidence of any sort of failure in any coating including, but not limited to, lifting of coats or loss of adhesion between layers in coating system.
The adhesion pull-off test shall be conducted accordance with ASTM D4541. The Coating which adhesion pull off test result is less than 30kg/cm² (3MPa) shall be considered to have failed.
10.3.5 Porosity check Film continuity shall be checked as follows,
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
Page 14 of 16
REFINERY TANK FARM PACKAGE 6
Visual Inspection for holidays, pinholes, and excessive overspray shall be done by CONTRACTOR Painting Inspector for every subsequent coat and after completion of Final coat.
Areas found to have been improperly coated shall be reapplied as per section 11 in this procedure.
10.3.6 Soluble salt contamination This test shall be done, once for every different Grade Material after surface preparation has been completed and prior to coating application. Testing for chloride and soluble salt concentrations shall be done using a Bresle Method according to ISO 8502-6. The pH level shall be find using of pH paper or pH meter. The chloride and soluble salt concentrations shall be less than 10 ppm and the pH shall be natural (between 6 and 8). When the above ppm & pH levels are exceeded, the surfaces shall be either steam cleaned or high pressure water washed before blasting. The cleaned surface shall be retested to that the contaminant levels are within the acceptable range. The above test shall be carried out by the CONTRACTOR Painting Inspector and the result shall be recorded in the Coating/Blasting report (Ref. ATTACHMENT-1). 10.3.7 Testing Equipment Testing equipment shall be properly calibrated as per the Project Equipment Calibration Procedure (Ref. SA-JER-TFAAA-PSCL-506669). 11. REPAIR OF DEFECTS OR DAMAGES 11.1 Any defect or damage that may occur shall be repaired before the application of further coats. 11.2
Areas which are to be over coated shall be thoroughly cleaned free from grease, oil and other contaminants and shall be dry.
11.3
The surfaces shall then be prepared to the standard as specified. Edges of sound coating around the repair area shall be feathered back approximately 50 mm for a smooth transition. If necessary, vacuum blasting equipment shall be used for surface preparation.
11.4
Subsequently additional compatible coats shall be applied (if required), until they meet the specification. Those additional coats shall blend in with final coating on adjacent area
11.5
Damaged surface shall be touchup with the coating as per the approved specification (Ref. SA-JER-TRAAA-PSCL-648020) or Coating Manufacturers’ Recommended paints shall be used. The repair coat shall overlap sound coating.
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
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REFINERY TANK FARM PACKAGE 6
12. COLOUR SCHEDULE 12.1 The coating colour shall be strictly followed as per the COMPANY approved Blasting & Painting Specification for Steel structural (Ref. SA-JER-TRAAA-PSCL-648020). 13. HEALTH, SAFETY & ENVIRONMENT 13.1
All work shall strictly comply with Project Health, Safety & Environmental Plan (SAJER-TFAAA-PSCL-498143) and Shop Safety Rules & Regulations. Grit blast hoses and nozzle shall be grounded to dissipate a static electric charge.
13.2
Anti-whip devices shall be fitted to all air hoses.
13.3
Safety shields, helmets, goggles, respirators, ear protection and protective clothing shall be use or worn then and where necessary during all operations.
13.4
Material Safety Data Sheet shall be always available at coating area for ready reference.
13.5
Only competent personnel are permitted to operate the equipment and such persons shall be tested by a competent person.
13.6
To prevent uncontrolled and reduce air emissions, the works shall be conducted in a controlled environment.
13.7
Abrasive shall be reused where possible, so as to reduce waste generated.
13.8
Waste generated such as paint containers, spent abrasive shall be properly stored prior to removal by approved waste collectors.
14. RECORD 14.1 The entire process shall be assured by CONTRACTOR PAINTING INSPECTOR by recording all the variables in the Blasting / Coating Report – PSCL-SATORP-QAQC010 (Ref. Attachment -1) 15. ATTACHMENTS 15.1 ATTACHMENTS – 1 Blasting / Coating Report (PSCL-SATORP-QAQC-010)
Doc No: SA-JER-TFAAA-PSCL-508022 Rev.00
Title: BLASTING AND PAINTING PROCEDURE FOR STRUCTURAL STEEL
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